Northern Lights NL773LW3 Parts Manual

P773-3

For Models: M773LW3 and NL773LW3

PARTS CATALOG

Marine Generators | Marine Diesel Engines | Land-Based Generators

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W. Seattle, WA 98107 Tel: (206) 789-3880 Fax: (206) 782-5455

Printed in U.S.A. PART NO.: P773-3 07/08

PARTS CATALOG

for Models

M773lw3 and NL773lw3

Please read thoroughly before aempting to use this manual:

Table of Contents ........................................................................................................................................... 1

Model Designation & Serial Numbers .............................................................................................................. 2

Reading a Parts Page ...................................................................................................................................... 3

Table of Contents

GROUP 1 - ENGINE

Cylinder Block Assembly ..........................0 - 3

Crankshaft Assembly ................................ 4 - 5

Oil Pump & Pick-up ...................................... 6

Camshaft ...................................................... 7

Cylinder Head ............................................... 8

Rocker Arm Cover & Assembly ............... 9 - 11

GROUP 2 - INTAKE & EXHAUST SYSTEM

Air Filter & Housing ................................. 0 - 1

Mufer ......................................................... 2

GROUP 3 - COOLING

Coolant Recovery Tank .................................. 1

Heat Exchanger & Exhaust Manifold ......... 2 - 3

Coolant Pump ......................................... 4 - 5

Raw Water Pump & Mounting ........................ 6

Raw Water Pump Assembly ............................ 7

Radiator & Guard .....................................8 - 9

GROUP 4 - FUEL SYSTEM

Injection Pump & Lines ...........................0 - 1

Governor & Timing Gear Case .................. 2 - 5

Fuel Filter & Piping ................................. 6 - 7

Fuel Line Connection .................................... 8

Fuel Injector .................................................. 9

Fuel Feed Pump .......................................... 10

GROUP 5 - ELECTRICAL SYSTEM

12 & 24 Volt, Standard & Isolated Ground .. 0 - 7

Alternator Mounting & Assembly ....... 8, 14 -15

Starter & Alternator .............................. 10 - 11

Starter, Alternator, & Flywheel Housing ........ 12

Starting Motor Assembly .............................. 16

Control Panels ...................................... 17 - 19

Belt Guard Assembly ............................ 20 - 21

GROUP 6 - GASKET SETS

Gasket Sets ..........................................................0

GROUP 7 - GEAR AND ADAPTER SETS Not available at this time.

GROUP 8 - FRAME & MOUNTING

Base Frame Assembly .................................... 1

GROUP 9 - ACCESSORIES

GROUP 9 - & OPTIONAL EQUIPMENT

Oil Drain Kit ................................................. 0

Keel Cooling Conversion Kit .......................... 1

Proprietary Information

This publication is the sole property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or part without the expressed written permission of Alaska Diesel Electric, Inc.

P773-3 07/08

I

Model Designation

MODELS INCLUDED

This manual covers the operating instructions for:

M773LW3 and NL773LW3

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

M - NL 773 L, W 3

M - Northern Lights Marine generator set NL - Northern Lights Industrial generator set

M773LW3

Northern Lights marine diesel generator set

= =

with an 773 engine and a PX-309K2 generator with a different winding, Tier III.

Model number of engine block Bore Cylinders 77 mm 3

NL773LW3

Designates long

stroke

and winding

in generator.

Northern Lights industrial diesel generator set with an 773 engine and a PX-309K2 generator with a different winding, Tier III.

Designates

Tier III

Serial Numbers

Your set has three serial numbers: 1 an engine number stamped on the block, 2 a generator plate and, 3 a generator set plate. Use the serial number on the generator set plate when ordering parts or in correspondence. The generator set plate is found on the service side of the generator and resembles the drawing below.

P773-3 07/08

II

Reading a Parts Page

IMPORTANT:

Before selecting parts, be sure that you are choosing parts from the correct page.

Check the model designation at the page top.

Do not use this illustration for parts purchasing.

1

ELECTRICAL SYSTEM

ALTERNATOR ASSEMBLY: M - NL773

4

6

5

KEY PART NUMBER QTY. DESCRIPTION SERIALNUMBER

0 185046210 1 Alternator Assembly 1 185446219 1 Flywheel, complete 2 185446217 1 Plate, complete 3 185716200 1 Plate 4 185446218 1 Stator, complete 5 040126210 2 Bearing 6 020210010 1 Nut 7 027100010 1 Spring washer 8 026100010 1 Washer 9 185446220 1 Clamp 10 015140408 1 Screw 11 015140425 2 Screw 12 199236510 1 Collar -

7

8 9

10

23

13

11

P773 06/02

5-2

14

12

REFERENCES:

1. Grouping section title. 7. Quantity of parts used.

2. Model designation of equipment that uses parts 8. Description of each component part.

 listedonthispage. 9. Serialnumberofunitthepartts.

3. Title and description of assembly. 10. Assembly or kit designated by •• or •.

4. Drawing numbers that correspond to key 11. Grouping index number.

 columnnumbersforpartsidentication. 12. Pagenumberwithinthegroupingindex.

5. Key column for locating parts shown on drawing. 13. Manual title.

6. Part number. 14. Page publication date.

NOTE: a Arrows always point toward the front of the engine.

P773-3 07/08

III

GROUP 1 – ENGINE

Cylinder Block Assembly

M773LW3

P773-3 07/08

1 - 0

773cyl

GROUP 1 – ENGINE

Cylinder Block Assembly

M773LW3

KEY PART NUMBER QTY DESCRIPTION S/N

1 110103541 1 Cylinder Block Assembly (Includes keys #2 - #21) 2 198466050 1 Plug 3 064210025 1 Expansion Plug, 25 mm 4 064210035 2 Expansion Plug, 35 mm 5 064210015 1 Expansion Plug, 15 mm 6 198466010 4 Plug 7 064210040 2 Expansion Plug, 40 mm 8 198466030 4 Plug 9 165296142 1 Idle Gear Shaft Assembly 10 110708620 1 Oil Pan 11 198517592 1 Bushing; S.T.D. 198517596 1 Bushing; U.S. 0.25 198517599 1 Bushing; U.S. 0.50 12 040106203 1 Bearing 13 064100045 1 Expansion Plug, 45 mm 14 042303015 1 Bearing 15 036509005 1 Snap Ring 16 030500512 2 Dowel Pin 17 030500616 2 Dowel Pin 18 030501025 2 Dowel Pin 19 030309005 2 Spring Pin 20 012100620 2 Stud 21 012100635 1 Stud 22 012110660 1 Stud 23 110996800 1 Gasket 24 050209107 1 Oil Seal 25 198736050 1 Drain Cock 26 140546020 1 Joint 27 24-02001 1 Oil Filter 28 120116160 6 Tappet 29 120456222 6 Push Rod 30 140036220 1 Relief Valve Assembly 31 052109078 1 O-ring 32 068115200 1 Tube 33 198486770 1 Bushing 34 010109235 20 Capscrew, Hex Head M6 x 1.0 x 14 mm 35 110756490 1 Dipstick Tube 36 011310612 1 Bolt 37 198416270 1 Dipstick 38 052109113 2 O-ring 39 21-00003 1 Cap 40 23-78601 1 Bracket 41 15-00302 1 Lock Washer 3/8 42 12-00311 1 Capscrew, Hex Head 3/8-16 x 3/4" 43 18-72004 1 Oil Drain Hose -

(with Lock Washer) -

P773-3 07/08

1 - 1

GROUP 1 – ENGINE

Cylinder Block Assembly

NL773LW3

P773-3 07/08

1 - 2

NL773cylblock

GROUP 1 – ENGINE

Cylinder Block Assembly

NL773LW3

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 110101520 1 Cylinder Block Assembly - (includes keys #2- 21) 2 198466050 1 Plug 3 064210025 1 Expansion Plug, 25 mm 4 064210035 2 Expansion Plug, 35 mm 5 064210015 1 Expansion Plug, 15 mm 6 064210040 2 Expansion Plug, 40 mm 7 198466010 4 Plug 8 198466030 4 Plug 9 165296142 1 Idle Gear Shaft 10 110701110 1 Oil Pan 11 198517592 1 Bushing, Standard 198517596 1 Bushing, Undersize 0.25 mm 198517599 1 Bushing, Undersize 0.50 mm 12 040306203 1 Bearing 13 064100045 1 Expansion Plug, 45 mm 14 042303015 1 Needle Bearing 15 036509005 1 Snap Ring 16 030500512 2 Dowel Pin 17 030500616 2 Dowel Pin 18 030501025 2 Dowel Pin 19 030309005 2 Spring Pin 20 012110620 2 Stud Bolt 21 012110635 1 Stud Bolt 22 012110660 1 Stud Bolt 23 110996800 1 Gasket 24 050209107 1 Oil Seal 25 198736050 1 Drain Cock 26 140546020 1 Filter Joint 27 24-02001 1 Oil Filter 28 120116160 6 Tappet 29 120456222 6 Push Rod 30 140036220 1 Relief Valve Assembly 31 052109078 1 O-ring 32 068115200 1 Tube 33 198486770 1 Bushing 34 010109235 20 Bolt 35 010109238 2 Plug 36 025100016 2 Seal Washer 37 110756490 1 Dipstick Tube 38 052109113 2 O-ring 39 011310612 1 Bolt 40 198416270 1 Dipstick -

-

P773-3 07/08

1 - 3

GROUP 1 – ENGINE

Crankshaft Assembly

P773-3 07/08

1 - 4

773crankshaft

GROUP 1 – ENGINE

Crankshaft Assembly

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 115256830 1 Crankshaft Assembly (includes keys #2 - 5) 2 115276180 1 Crankshaft Gear 3 034100508 1 Key 4 030509020 1 Dowel Pin 5 030300816 1 Spring Pin 6 110156400 1 Bearing Holder Assembly 7 110156410 1 Bearing Holder Assembly 8 110156420 1 Bearing Holder Assembly 9 030500612 6 Dowel Pin 10 198517582 3 Bearing; Lower S.T.D. 198517586 3 Bearing; Lower U.S. 0.25 mm 198517589 3 Bearing; Lower U.S. 0.50 mm 11 198517572 3 Bearing; Upper S.T.D. 198517576 3 Bearing; Upper Undersized 0.25 mm 198517579 3 Bearing; Upper Undersized 0.50 mm 12 010810840 4 Bolt 13 010810845 2 Bolt 14 011510840 2 Bolt 15 010700835 2 Bolt 16 115107900 3 Ring Kit; S.T.D. 115107430 3 Ring Kit; Oversized 0.50 mm 17 115017460 3 Piston Kit; S.T.D. 115017450 3 Piston Kit; Oversized 0.50 mm 18 115326231 3 Piston Pin 19 036500021 6 Snap Ring 20 115026340 3 Connecting Rod Assembly 21 198517125 3 Bushing 22 115176150 6 Connecting Rod Bolt 23 020109075 6 Nut 24 198517602 6 Bearing; S.T.D. 198517606 6 Bearing; Undersized 0.25 198517609 6 Bearing; Undersized 0.50 25 115396650 1 Crankshaft Pulley 26 020800018 1 Nut 27 115356720 1 Flywheel Assembly 28 115376130 1 Ring Gear 29 010109340 6 Bolt -

(includes keys #9 & 12) - (includes keys #9 & 12) - (includes keys #9 & 13) -

(includes keys #21 - 23) -

(includes key #28) -

P773-3 07/08

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GROUP 1 – ENGINE

Oil Pump & Pick-up

Fig. 1-4

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 165026100 1 Idle Gear Assembly - 2 199266180 1 Thrust Washer 3 198216821 1 Spring 4 140166130 1 Rotor 5 140116140 1 Oil Pump Cover 6 199286150 ** Shim, 0.1 mm 199286160 ** Shim, 0.15 mm 199286170 ** Shim, 0.2 mm 199286180 ** Shim, 0.5 mm 7 198216720 1 Spring 8 199236540 1 Collar 9 036800010 1 Snap Ring 10 165166240 1 Front Plate 165166191 1 Front Plate

(Marine) - (Industrial) -

11 165996520 1 Gasket 12 011310612 3 Bolt 13 052109076 1 O-ring 14 140986830 1 Oil Pipe 15 140406500 1 Pick-up 16 011310612 2 Bolt -

**

As required

P773-3 07/08

1 - 6

GROUP 1 – ENGINE

Camshaft

Fig. 1-5

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120026830 1 Cam Shaft Assembly (includes keys #2- 6) - 2 120016021 1 Cam Gear Assembly 3 034100508 1 Key 4 120736081 1 Gear 5 199216230 3 Spacer 6 040109059 1 Bearing 7 125256120 1 Slider 8 199566651 1 Plate 9 010700610 1 Bolt 10 011310612 1 Bolt -

P773-3 07/08

1 - 7

GROUP 1 – ENGINE

Cylinder Head

773cylhead

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111011620 1 Cylinder Head Assembly (Marine, includes keys #2-3, 6-13, & 19) 111011630 1 Cylinder Head Assembly

(Industrial, includes keys #2 -3, 6-13, & 19) -

2 064210018 8 Expansion Plug 3 064210030 2 Expansion Plug 6 120166360 3 Intake Valve 7 120176250 3 Exhaust Valve 8 120406070 3 Valve Guide Seal - Intake 9 198216700 6 Spring 10 120186080 6 Retainer 11 120226070 12 Cotter 12 120406050 3 Valve Guide Seal - Exhaust 13 120216041 6 Cap 14 111147560 1 Head Gasket, t=1.2 mm 111147570 1 Head Gasket, t=1.3 mm 15 111136440 11 Head Bolt 16 111136450 3 Head Bolt 17 195816540 1 Lifting Eye 18 011510816 1 Bolt 19 110136300 3 Valve Seat - Intake 110136435 3 Valve Seat - Intake

- (Marine) - (Industrial) -

P773-3 07/08

1 - 8

GROUP 1 – ENGINE

Rocker Arm Assembly

773rockercover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 120037130 1 Rocker Arm Assembly (Marine, includes keys #2- 7, 16,17,19, & 20) 120037170 1 Rocker Arm Assembly

(Industrial, includes keys #2-7, 16,17,19, & 20) -

2 120356200 3 Intake Rocker Arm 3 120356210 3 Exhaust Rocker Arm 4 199486220 6 Screw 5 020109076 6 Nut 6 120316300 1 Rocker Arm Shaft 7 198216780 2 Spring 8 011310625 2 Bolt 9 012109177 3 Stud Bolt 10 023100008 3 Nut 11 1 Oil Pressure Switch

(see Electrical System) -

12 140607270 1 Oil Pipe 13 140996260 4 Gasket 14 198486780 1 Eye Bolt 15 120996150 1 Gasket 16 052100120 1 O-ring 17 199280280 4 Shim 18 198487590 1 Banjo Bolt

(Tapped 1/8 NPT Female) -

19 198436150 1 Plug 20 015100410 1 Screw -

P773-3 07/08

1 - 9

GROUP 1 – ENGINE

Rocker Arm Cover

M773LW3

773rockerarmcover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111217960 1 Rocker Arm Cover 2 111996420 1 Gasket -

 3 110666220 1 Bafe -

4 110666060 1 Vent Filter 5 015600406 4 Screw 6 140996260 3 Gasket 7 024600008 3 Cap nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Valve 11 011100408 4 Bolt 12 011310680 3 Bolt 13 011310625 2 Bolt 14 135566610 1 Air Intake 15 135996750 1 Gasket 16 011310620 2 Bolt 17 390190460 1 Caution Label -

P773-3 07/08

1 - 10

GROUP 1 – ENGINE

Rocker Arm Cover & Intake

NL773LW3

773rockerarmcover

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 111210140 1 Rocker Arm Cover 2 111996420 1 Gasket -

 3 110666220 1 Bafe -

4 110666060 1 Breather Element 5 015600406 4 Screw 6 140996260 3 Gasket 7 024600008 3 Cap Nut 8 198436010 1 Cap 9 052100400 1 O-ring 10 110566080 1 Valve, Breather 11 011100408 4 Bolt 12 011310680 3 Bolt 13 011310625 2 Bolt 14 135566630 1 Air Intake 15 135996750 1 Gasket 16 011310620 2 Bolt -

P773-3 07/08

1 - 11

GROUP 2 – INTAKE AND EXHAUST

Air Filter and Housing

M773LW3

A-10836C / C-5742

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 10-28202 1 Housing 2 18-28201 1 Hose 1- 5/8” ID x 1- 3/4” 3 Ply Silicone 3 19-01024 2 Hose Clamp #24 4 28-28601 1 Silencer Plate 5 10-28603 1 Cover 6 12-09124 4 Capscrew, Hex Head M6 x 1.0 x 50 mm S/S 7 15-01134 8 Flat Washer M6 S/S 8 24-28601 1 Screen 9 24-28602 1 Air Filter Element 10 10-28602 1 Cover 11 12-09131 4 Capscrew, Hex Head M6 x 1.0 x 20 mm S/S 12 18-28601 1 Hose, Air Intake 13 19-70022 1 Cushion Clamp #22 14 12-09751 1 Capscrew, Hex Head M8 x 1.25 x 16 mm S/S 15 15-00706 1 Flat Washer M8 S/S 16 12-09712 4 Capscrew, Hex Head M8 x 1.25 x 25 mm 17 15-00705 4 Lock Washer, Helical M8 S/S 18 15-00706

2 Flat Washer M8 S/S -

P773-3 07/08

2 - 0

GROUP 2 – INTAKE & EXHAUST SYSTEM

Air Filter and Housing

NL773LW3

773aircleaner

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 135016310 1 Air Cleaner Assembly (includes keys #9-12) 2 198756130 2 Hose Band 3 135597900 1 Hose 4 135976610 1 Bracket 5 199236730 1 Collar 6 011510825 2 Bolt 7 011510820 2 Bolt 8 131976050 1 Bracket 9 135326200 1 Filter Housing 10 24-27301 1 Element 11 135326201 1 Cover 12 314531163 1 Valve -

P773-3 07/08

2 - 1

GROUP 2 – INTAKE & EXHAUST SYSTEM

Exhaust Manifold & Mufer

NL753W2

773exhmanifold

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 135046212 1 Exhaust Manifold Assembly (includes keys #2- 5) -

2 135616832 1 Exhaust Manifold 3 135996900 1 Gasket 4 135406170 1 Housing 5 011310612 10 Bolt 6 135996541 1 Gasket 7 027100006 4 Spring Washer 8 012109215 2 Stud 9 023100006 2 Nut 10 010109381 4 Bolt 11 020900008 1 Nut 12 026100008 2 Washer 13 408330011 1 Band 14 010310850 1 Bolt 15 135606150 1 Exhaust Elbow 27-38200 1 Exhaust Elbow, 1- 1/4 NPT 16 010109407 1 Bolt -

P773-3 07/08

(optional) -

2 - 2

GROUP 3 – COOLING SYSTEM

Coolant Recovery Tank

A-9347/ B-8741

KEY PART NUMBER QTY DESCRIPTION SERIAL NUMBER

1 310550130 1 Coolant Recovery Tank 2 222300090 1 Coolant Recovery Tank Mounting Bracket 3 19-18602 2 Hose Clamp 4 12-00030 2 Capscrew, Hex Head, M6 x 1.0 x 16 mm 5 15-01132 2 Lock Washer 6 27-18601 1 Tube 5/16" ID x 23" Polyurethane 7 18-18602 1 Hose 5/16" ID x 28" Polyvinyl 8 19-18602 1 Hose Clamp -

P773-3 07/08

3 - 1

Northern Lights NL773LW3 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual